Yamaha XTZ660 1993-1996 Factory Service Repair Manual
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Basic Information Identification Make: Yamaha Model: XTZ660 Model Generation: First Generation (1991-1999) Model Years Covered: 1993, 1994, 1995, 1996 Vehicle Type: Dual-sport Motorcycle Engine Type: Four-stroke, single-cylinder Codes Engine Code: 3TB (typical for this generation) Introduction Market Position Target Audience: Yamaha XTZ660 owners and mechanics seeking factory-level repair and maintenance information. Competitive Analysis Value Proposition: Provides complete, authentic factory data, enabling owners to perform repairs and maintenance, saving significant labor costs compared to professional shop rates. Key Features Feature 1: Authentic factory service information. Feature 2: Comprehensive coverage of all vehicle systems. Feature 3: Detailed step-by-step instructions with illustrations. Feature 4: Advanced troubleshooting guide. Feature 5: Printable format for convenience in the workshop. Manual Details Coverage Areas Primary Coverage: Complete factory service and repair for Yamaha XTZ660 models from 1993-1996. Secondary Coverage: Troubleshooting, diagnostics, maintenance, and repair of all systems. Page Count Estimated Page Count: Hundreds of pages (specific count not provided, but described as comprehensive) Manual Type Type: Factory Service Repair Manual Authenticity: Actual Genuine Factory Manuals (not 3rd party) Language Language: English Format Digital Format: PDF Download Manual Coverage Systems Covered Engine And Powertrain: General Information, Fuel System, Cooling System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Final Drive Chassis And Suspension: Wheels/Tires, Brakes, Suspension, Steering, Frame Electrical And Diagnostics: Electrical System, Wiring Diagrams, Engine Management Systems, Fault Diagnosis Accessories And Bodywork: Implied coverage of all aspects of the vehicle, including any bodywork or accessory systems relevant to repair and maintenance. Procedures Included Maintenance: Routine maintenance, fluid changes, inspections, lubrication. Repair: Step-by-step repair procedures for all covered systems, component overhauls, and part replacements. Diagnostics And Troubleshooting: Fault symptom diagnosis, testing suspected parts, troubleshooting guides, engine management system analysis. Tuning And Adjustment: Implied coverage for engine tuning and adjustment procedures within the engine management system section. Technical Depth Depth: Comprehensive, covering fundamentals to advanced diagnostics and repair, mirroring factory technician knowledge. Illustration Support: Detailed illustrations, drawings, photos, and enlarged insets for component identification and procedure guidance. Manual Specifications File Format Format: PDF Compatibility: Compatible with all PC-based Windows operating systems and Mac. Print Quality Printability: Fully printable, allows printing of individual pages, chapters, or the entire manual without restriction. Searchability Search Functionality: Searchable PDF for quick information retrieval. Delivery Method Delivery: Instant download link provided upon completion of payment. Dependencies Software Requirement: Adobe PDF Reader Binding Type Binding: N/A (Digital Download - printable) Paper Type Paper Type: N/A (Digital Download - printable) Engine Specifications Primary Engine Engine Configuration: Single-cylinder, four-stroke, liquid-cooled, DOHC Displacement: 660cc (659cc typically) Bore X Stroke: Approx. 100 mm x 84 mm (specific values to be found in manual) Compression Ratio: Approx. 8.8:1 to 9.0:1 (specific value to be found in manual) Performance Horsepower: Approx. 47-50 PS (35-37 kW) at 6000-6500 rpm (varies by market and tuning) Torque: Approx. 5.6-5.9 kgf-m (55-58 Nm) at 5000-5500 rpm (varies by market and tuning) Fuel System Fuel Delivery: Carburetor (typically Mikuni BST34 or similar) Fuel Type: Unleaded gasoline (octane rating specified in manual) Fuel Tank Capacity: Approx. 20 liters (5.3 US gal) (specific value to be found in manual) Transmission Standard Transmission Type: Constant mesh 5-speed Optional Optional Transmissions: N/A Features Clutch Type: Wet, multiple-disc Final Drive: O-ring sealed chain drive Dimensions Exterior Length: Approx. 2230 mm (87.8 in) (specific value to be found in manual) Width: Approx. 830 mm (32.7 in) (specific value to be found in manual) Height: Approx. 1350 mm (53.1 in) (specific value to be found in manual) Wheelbase: Approx. 1465 mm (57.7 in) (specific value to be found in manual) Weights Dry Weight: Approx. 179 kg (395 lbs) (specific value to be found in manual) Wet Weight: Approx. 196 kg (432 lbs) (with oil and full fuel tank, specific value to be found in manual) Maximum Load: To be specified in the manual Safety Features Ratings Safety Ratings: Not applicable in the traditional automotive sense; focuses on mechanical integrity and operational safety. Active Features Active Safety: Disc brakes, capable suspension system designed for varied terrain. Passive Features Passive Safety: Sturdy frame construction, rider ergonomics promoting control. Technology Features Infotainment Infotainment Features: Basic instrumentation: speedometer, tachometer, odometer, trip meter, indicator lights. No advanced infotainment systems present. Driver Assistance Driver Assistance Features: None. Relies on rider input and mechanical systems. Connectivity Connectivity Features: None. Lighting Headlight Type: Halogen bulb (specific wattage to be found in manual). Taillight Type: Incandescent bulb (specific wattage to be found in manual). Maintenance Service Intervals Oil Change Interval: Refer to manual for specific mileage/time interval, typically around 3,000-5,000 km (1,800-3,000 miles) or 6 months. Air Filter Cleaning: Refer to manual, typically every 5,000-10,000 km (3,000-6,000 miles). Spark Plug Replacement: Refer to manual, typically every 10,000-20,000 km (6,000-12,000 miles). Fluid Specifications Engine Oil Type: Yamalube 4 (or equivalent SAE 10W-40 or 20W-40 API SG or higher). Engine Oil Capacity:...
Basic instrumentation: speedometer, tachometer, odometer, trip meter, indicator lights. No advanced infotainment systems present.
Driver Assistance
Driver Assistance Features:
None. Relies on rider input and mechanical systems.
Connectivity
Connectivity Features:
None.
Lighting
Headlight Type:
Halogen bulb (specific wattage to be found in manual).
Taillight Type:
Incandescent bulb (specific wattage to be found in manual).
Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific mileage/time interval, typically around 3,000-5,000 km (1,800-3,000 miles) or 6 months.
Air Filter Cleaning:
Refer to manual, typically every 5,000-10,000 km (3,000-6,000 miles).
Spark Plug Replacement:
Refer to manual, typically every 10,000-20,000 km (6,000-12,000 miles).
Fluid Specifications
Engine Oil Type:
Yamalube 4 (or equivalent SAE 10W-40 or 20W-40 API SG or higher).
Engine Oil Capacity:
Approx. 2.4 liters (2.5 US qt) with filter change (specific value to be found in manual).
Coolant Type:
Ethylene glycol based antifreeze solution (specific Yamaha coolant or equivalent).
Brake Fluid Type:
DOT 4 brake fluid.
Known Issues
Common Issues:
Stator failures, regulator/rectifier issues, potential for worn valve guides or seats over high mileage, carburettor jetting sensitivity to altitude/modifications.
Maintenance Tips:
Regularly check chain tension and lubrication, inspect for oil leaks, ensure cooling system is clean and free of blockages.
Vehicle History
Brand Heritage
Yamaha Motorcycles:
Yamaha Motor Corporation has a long and distinguished history in motorcycle manufacturing, known for innovation, performance, and reliability across various disciplines, including off-road and adventure touring.
Model Evolution
Xtz Lineage:
The XTZ660 is part of Yamaha's 'Tenere' family of dual-sport motorcycles, originally developed with inspiration from rally racing, offering a balance of on-road comfort and off-road capability.
Xtz660 Development:
The XTZ660 was introduced to compete in the middleweight adventure touring segment, offering a robust single-cylinder engine suitable for long-distance travel and varied terrain.
Production
Production Period:
1991-1999 for the first generation.
Manufacturing Location:
Primarily Japan.
Awards & Recognition
Recognitions
Industry Recognition:
Not specifically documented in the provided product information, but the model is recognized for its dual-sport capabilities and reliability.
Ratings
Performance Ratings:
Praised in contemporary reviews for its strong single-cylinder torque, comfortable riding position, and versatility for adventure touring and off-road use.
Certifications
Emissions Certification:
Compliant with emissions standards relevant to its production years and market of sale; specific details would be in the manual or original documentation.
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